Method and system for mortar removal

ABSTRACT

A method and system for removing mortar from a plurality of joints between a plurality of masonry units in a masonry structure, incorporating a suspension work platform, a work tool, and an articulating arm system ( 500 ).

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of the previously filed U.S. patentapplication Ser. No. 14/834,416 filed Aug. 24, 2015, which is acontinuation-in-part of the previously filed U.S. patent applicationSer. No. 13/955,074, filed Jul. 31, 2013, which is a continuation of thepreviously filed U.S. patent application Ser. No. 12/961,942, filed Dec.7, 2010, now U.S. Pat. No. 8,527,103, and claims the benefit of thepreviously filed applications under 35 U.S.C. §120. Related applicationconcerning suspension platform systems is U.S. Pat. No. 9,217,254, filedon Dec. 23, 2013, and is incorporated by reference herein in itsentirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

TECHNICAL FIELD

The present disclosure relates to the field of masonry and masonryrestoration, and more particularly, to a method and system for removingmortar from a plurality of joints between a plurality of masonry unitsin a masonry structure.

BACKGROUND OF THE INVENTION

Over time, every masonry structure will require the mortar betweenmasonry joints to be removed and replaced with new mortar. The mortarbetween masonry joints is very important for a number of reasons. Forexample, the mortar provides the strength to hold the masonry unitstogether; it serves as a type of cushion between masonry units; and itprovides a water-resistant barrier to help prevent moisture and othercontaminants from entering the structure. Thus, when the mortar beginsto show signs of deterioration, it must be removed and replaced with newmortar to continue providing the above-enumerated benefits.

The process of removing the deteriorated mortar and replacing it withnew mortar is referred to as repointing, which is sometimes calledeither pointing or tuckpointing. Prior art methods of mortar removalutilize manual hand tools and powered hand tools. Such methods are verylabor intensive and time consuming, which makes the current repointingmethods very expensive. In addition, the process of removing thedeteriorated mortar from the masonry joints generates silica dust.Masonry workers who inhale silica dust run the risk of developingsilicosis, a disabling and many times fatal disease that affects thelungs.

What is needed in the art is a device for removing deteriorated mortarfrom masonry joints that is less labor intensive and time consuming andthat also reduces or eliminates the exposure of silica dust to theworker. The presently disclosed method and system for mortar removaladdresses these needs, as well as others.

SUMMARY OF THE INVENTION

In its most general configuration, the method and system for mortarremoval advances the state of the art with a variety of new capabilitiesand overcomes many of the shortcomings of prior devices in new and novelways. The method and system for mortar removal overcomes theshortcomings and limitations of the prior art in any of a number ofgenerally effective configurations. The method and system for mortarremoval demonstrates such capabilities and overcomes many of theshortcomings of prior devices and methods in new and novel ways.

The present disclosure relates to a method and system for removingmortar from a plurality of joints between a plurality of masonry unitsin a masonry structure. The steps for accomplishing the method includesensing the location of at least one of the plurality of joints betweenthe plurality of masonry units and transmitting joint location data to acomputer control system. Next, the computer control system computes awork path based upon the joint location data. In a further step, thecomputer control system controls the position and operation of at leastone work tool such that the at least one work tool moves along the workpath to remove mortar from at least a portion of one of the plurality ofjoints along the work path. Finally, the dust and debris generated whenthe at least one work tool removes mortar from at least a portion of oneof the plurality of joints along the work path is contained and removed.

The system for mortar removal generally includes a joint identificationdevice, at least one work tool, a containment system, and a computercontrol system that is in electrical communication with the jointidentification device and the at least one work tool. An access systemmay be provided to raise and lower the various components of the systemfor mortar removal along an exterior of the masonry structure.

The joint identification device is configured to sense the location ofat least one of the plurality of joints between the plurality of masonryunits and transmit joint location data to the computer control system.In a particular embodiment, the joint identification device comprises anoptical shape recognition sensor to optically sense the location of atleast one of the plurality of joints.

The at least one work tool is utilized to remove mortar from at least aportion of one of the plurality of joints between the plurality ofmasonry units. In one embodiment, a circular blade is used to removemortar from the joints. In another embodiment, a square bit may beutilized to remove mortar from the joints. Still further, in anotherembodiment, a tool changing system having a tool magazine for holding aplurality of work tools may be utilized to change out the at least onework tool used to remove mortar from the joints.

During mortar removal, a containment system may be utilized to collectdust and debris generated during the mortar removal process. Thecontainment system includes a suction hood for enclosing the at leastone work tool and for forming a seal against the masonry structure.Secured to the suction hood is a vacuum system for removing dust anddebris from the suction hood.

The general operation of the system for mortar removal is facilitated bythe computer control system. As previously mentioned, the computercontrol system is in communication with the joint identification deviceand the at least one work tool. The computer control system is capableof sending and receiving electrical signals representative of commandsand/or data to and from the joint identification device and the at leastone work tool. For example, the computer control system receives thejoint location data from the joint identification device and computes awork path based upon the joint location data. Further, the computercontrol system controls the position and operation of the at least onework tool such that the at least one work tool removes mortar from atleast a portion of one of the plurality of joints along the work path.

In one embodiment, the method may further include the step of brushingat least a portion of one of the plurality of joints along the work pathafter mortar has been removed. This step helps to properly prepare thejoints so that they may filled in with new mortar. In yet anotherembodiment, the method for mortar removal may include the step ofblowing air into at least a portion of one of the plurality of jointsalong the work path after mortar has been removed. Preferably this stepfollows the step of brushing the plurality of joints. Blowing air intothe joints further prepares the joints so that they may be filled inwith new mortar.

The presently disclosed method and system for mortar removal provides analternative to the prior art methods that are labor intensive and timeconsuming. The presently disclosed method and system for mortar removalalso promotes worker safety by containing contaminants and eliminatingthe risk of a worker developing carpal tunnel syndrome caused bygrinding the mortar by hand. Further, the method and system for mortarremoval will reduce injuries caused by the prior art hand tools utilizedto remove mortar from joints.

A work tool may be mounted on a tool support structure, which togetherwith a suspended work platform, may in turn be mounted on at least onemodular mast for elevated projects. The work tool may be suspended froman articulating arm system, and may be configured so that the work toolmay be independently adjusted in pitch, roll, yaw, elevation and cuttingdepth. The tool support platform and suspended work platform may both berepositioned as needed so that a larger number of joints may be reached.

BRIEF DESCRIPTION OF THE DRAWINGS

Without limiting the scope of the method and system for mortar removalas claimed below and referring now to the drawings and figures:

FIG. 1 is an elevation view of a portion of a masonry structure, not toscale;

FIG. 2 is a cross sectional view of a portion of a masonry structuretaken along section line 2-2 of FIG. 1, not to scale;

FIG. 3 is an elevation view of an embodiment of a system for mortarremoval, not to scale;

FIG. 4 is a partial schematic view of an embodiment of a system formortar removal, not to scale;

FIG. 5 is a partial schematic view of an embodiment of a system formortar removal, not to scale;

FIG. 6 is an elevation view of a portion of an embodiment of a systemfor mortar removal, not to scale;

FIG. 7 is a cross sectional view of a portion of an embodiment of asystem for mortar removal taken along section line 7-7 of FIG. 6, not toscale;

FIG. 8 is a cross sectional view of a portion of an embodiment of asystem for mortar removal, not to scale;

FIG. 9 is an elevation view of a portion of a masonry structure showinga work path, not to scale;

FIG. 10 is a flow chart illustrating an embodiment of a method formortar removal;

FIG. 11 is an elevation view of a portion of an embodiment of a systemfor mortar removal, not to scale;

FIG. 12 is an elevation view of a portion of an embodiment of a systemfor mortar removal, not to scale;

FIG. 13 is an elevation view of a portion of an embodiment of a systemfor mortar removal, not to scale;

FIG. 14 is an elevation view of a portion of an embodiment of a systemfor mortar removal, not to scale;

FIG. 15 is an elevation view of a portion of an embodiment of a systemfor mortar removal, not to scale;

FIG. 16 is an elevation view of a portion of an embodiment of a systemfor mortar removal, not to scale;

FIG. 17 is an elevation view of a portion of an embodiment of a systemfor mortar removal, not to scale;

FIG. 18 is an elevation view of a portion of an embodiment of a systemfor mortar removal, not to scale;

FIG. 19 is an elevation view of a portion of an embodiment of a systemfor mortar removal, not to scale;

FIG. 20 is an elevation view of a portion of an embodiment of a systemfor mortar removal, not to scale;

FIG. 21 is an elevation view of a portion of an embodiment of a systemfor mortar removal, not to scale; and

FIG. 22 is an elevation view of a portion of an embodiment of a systemfor mortar removal, not to scale.

These drawings are provided to assist in the understanding of theexemplary embodiments of the method and system for mortar removal asdescribed in more detail below and should not be construed as undulylimiting the system. In particular, the relative spacing, positioning,sizing and dimensions of the various elements illustrated in thedrawings are not drawn to scale and may have been exaggerated, reducedor otherwise modified for the purpose of improved clarity. Those ofordinary skill in the art will also appreciate that a range ofalternative configurations have been omitted simply to improve theclarity and reduce the number of drawings.

DETAILED DESCRIPTION OF THE INVENTION

The presently disclosed method and system (10) for mortar removalenables a significant advance in the state of the art. The preferredembodiments of the method and system (10) accomplish this by new andnovel arrangements of elements and methods that are configured in uniqueand novel ways and which demonstrate previously unavailable butpreferred and desirable capabilities. The description set forth below inconnection with the drawings is intended merely as a description of theembodiments of the claimed method and system (10), and is not intendedto represent the only form in which the method and system (10) may beconstructed or utilized. The description sets forth the designs,functions, means, and methods of to implementing the method and system(10) in connection with the illustrated embodiments. It is to beunderstood, however, that the same or equivalent functions and featuresmay be accomplished by different embodiments that are also intended tobe encompassed within the spirit and scope of the claimed method andsystem (10).

Referring generally to FIGS. 1-10, the method for removing mortar from aplurality of joints (J) between a plurality of masonry units (MU) in amasonry structure (MS) includes a system (10) for mortar removal. Thesystem (10) is configured to remove mortar from at least a portion ofone of the plurality of joints (J) so that the joint (J) may be filledwith new mortar. Referring now to FIG. 10, in a general embodiment, thesteps for accomplishing the method include sensing the location of atleast one of the plurality of joints (J) between the plurality ofmasonry units (MU) and transmitting joint location data to a computercontrol system (400). Next, the computer control system (400) computes awork path (WP) based upon the joint location data. In a further step,the computer control system (400) controls the position and operation ofat least one work tool (200) such that the at least one work tool (200)moves along the work path (WP) to remove mortar from at least a portionof one of the plurality of joints (J) along the work path (WP). Finally,the dust and debris generated when the at least one work tool (200)removes mortar from at least a portion of one of the plurality of joints(J) along the work path (WP) is contained and removed.

A portion of a common masonry structure (MS) is illustrated in FIGS. 1and 2. The masonry structure (MS) comprises a plurality of masonry units(MU) that are separated by a plurality of joints (J) filled with mortar.The masonry units (MU) may be formed of any material that is used in themasonry industry, including but not limited to, clay bricks, naturalstone, stone veneer, ceramic bricks, cement blocks, and fly ash bricks,just to name a few. The mortar is used to bind the masonry units (MU)together and is typically formed of a mixture of sand, a binder such ascement or lime, and water. The mortar is typically softer than themasonry units (MU), and over time will begin to deteriorate, primarilydue to water penetration and freeze-thaw cycles. As a result, it becomesnecessary to remove the deteriorated mortar from the plurality of joints(J) and to fill in the plurality of joints (J) with new mortar. Itshould be noted that not all of the mortar from the plurality of joints(J) is removed; rather, a predetermined depth of mortar is removed,which is typically about 0.75 inches to about 1.0 inch. In mostinstances, the plurality of joints (J) comprise long horizontal jointsthat extend substantially along the X-axis, as seen in FIG. 1, and shortvertical joints that extend substantially along the Y-axis, also seen inFIG. 1. The presently disclosed system (10) is effective for removingmortar from the plurality of joints (J) at a predetermined depth so thatthe plurality of joints (J) may be filled in with new mortar.

Referring now to FIG. 3, an embodiment of the system (10) for mortarremoval is shown. The system (10) generally includes a jointidentification device (100), at least one work tool (200), a containmentsystem (300) (seen in FIGS. 4 and 5), and a computer control system(400) (seen in FIGS. 4 and 5). The joint identification device (100) andthe at least one work tool (200) are in electrical communication withthe computer control system (400), as seen in FIG. 4. Referring again toFIG. 3, the system (10) may also include an access system (50) to raiseand lower the components of the system (10) along an exterior of themasonry structure (MS). Now, the components of the system (10) will bedescribed in greater detail.

The joint identification device (100) is configured to acquireinformation regarding the plurality of joints (J) between the pluralityof masonry units (MU) in the masonry structure (MS). For example, thejoint identification device (100) is capable of sensing the location ofat least one of the plurality of joints (J) between the plurality ofmasonry units (MU) and transmitting joint location data to the computercontrol system (400). In some embodiments the joint location data mayinclude the X, Y, and Z coordinates associated with at least one of theplurality of joints (J). In another embodiment, the joint identificationdevice (100) may be capable of sensing joint dimension data, includingthe length, width, and depth of at least one of the plurality of joints(J). The joint location and joint dimension data may be acquired in anumber of ways, including a remote joint identification device greaterthan ten feet from the masonry structure (MS), a set-off jointidentification device within ten feet of the masonry structure (MS) andcapable of automated movement controlled by the computer control system(400), or a local joint identification device positioned within two feetof the suction hood (310), or a combination of one or more of thesedevices.

In the local joint identification device embodiment, the device acquiresinformation about a joint (J) which may include identification of thelocation of edges of the masonry units (MU), as well as associated X, Y,and Z coordinates of the recessed corners of the mortar at theintersection with the adjacent masonry units (MU). The jointidentification device (100) may further identify the center of thejoint, as well as the distance that the work tool (200) is away from asurface of the mortar. Such information may be acquired in any number ofways. One particular embodiment includes a laser sensor systemconsisting of a laser and a camera in a single housing, and may furtherinclude a semi-conductor laser and a complimentary metal oxidesemiconductor (CMOS) type camera. One with skill in the art willappreciate that many other forms of joint profiling and tracking may beused. Further, the joint identification device (100) may incorporate offthe shelf systems or may incorporate custom configured systems designedto minimize the size of the overall apparatus.

In one particular embodiment, the joint identification device (100)comprises an optical sensor (110) to optically sense the location of atleast one of the plurality of joints (J) between the plurality ofmasonry units (MU), as seen in FIG. 5. The optical sensor (110) may be ahigh speed camera and frame grabber that captures images of at least oneof the plurality of joints (J) between the plurality of masonry units(MU). Alternatively, a still camera may also be utilized to capture atleast one image of the plurality of joints (J), and the still camera maybe remote to the system (10) or built into the system (10). Forinstance, a worker may take a digital image of the masonry structure(MS) which is then uploaded into the system (10) and processed. Thecaptured image data, whether a single image or multiple images, may thenbe processed with appropriate shape recognition software to calculatejoint location data that is transmitted to the computer control system(400); or alternatively, the image may be transferred to the computercontrol system (400) where it is processed. Moreover, the optical sensor(110) may be configured to sense the shape, size and location of theplurality of masonry units (MU) to determine the location of at leastone of the plurality of joints (J). For example, a masonry structure(MS) may include masonry units (MU) of a uniform size, e.g., 3 inch by 8inch. An operator may manually input the size and shape data, e.g., 3inch by 8 inch rectangles, of the masonry units (MU) into the computercontrol system (400), or the system (10) may include a physical sensorthat tracks the perimeter of a masonry unit (MU) and loads the acquireddata into the computer control system (400). The optical sensor (110)may capture images of the plurality of masonry units (MU), which maythen be processed by appropriate software to identify the location ofthe masonry units (MU) by recognizing the size and shape of the masonryunits (MU). The spaces between the recognized masonry units (MU) willrepresent the location of the joints (J). Commercially available opticalsensors (110) that incorporate shape recognition include the INSIGHTseries vision systems and CHECKER series vision sensors available fromCognex Corporation of Natick, Mass.

In another embodiment, the joint identification device (100) may includea high speed camera and a laser to acquire 2D images and 3D profiles ofat least one of the plurality of joints (J). The laser may be asolid-state laser or a semiconductor laser, just to name a couple, andthe camera may be a CMOS type camera. In this embodiment, the jointidentification device (100) may acquire joint dimension datacorresponding to at least one of the plurality of joints (J) utilizinglaser-triangulation measurement, which is then transmitted to thecomputer control system (400). Alternatively, the captured 2D images and3D profiles of at least one of the plurality of joints (J) may beprocessed with appropriate software to calculate joint dimension datathat is transmitted to the computer control system (400). Examples ofcommercially available devices include the Laser Rut Measurement System(LRMS), Laser Road Imaging System (LRIS), and Laser Crack MeasurementSystem (LCMS) manufactured by Institut National D'Optique of Quebec,Canada.

As seen in FIG. 3, the joint identification device (100) may be movablymounted to a carrier frame (230) adjacent to the at least one work tool(200). In one embodiment, the carrier frame (230) includes at least onelongitudinal rail (231) movably mounted to and disposed between at leasttwo transverse rails (232). For example, a gear driven drive systempowered by stepper motors or servomotors may be secured to the at leastone longitudinal rail (231) and the at least two transverse rails (232)such that the at least one longitudinal rail (231) is capable of preciseand controlled movement along the at least two transverse rails (232) inthe X-axis direction, as seen in FIG. 3. Additionally, the jointidentification device (100) and the at least one work tool (200) mayeach be movably mounted to the at least one longitudinal rail (231) viaa gear driven drive system powered by stepper motors or servomotors sothat the joint identification device (100) and the at least one worktool (200) are capable of precise and controlled movement along the atleast one longitudinal rail (231) in the Y-axis direction, also seen inFIG. 3. In one embodiment, the joint identification device (100) and theat least one work tool (200) are mounted on the at least onelongitudinal rail (231) such that they are spaced apart, but lie on thesame horizontal axis. Such a carrier frame (230) comprising at least onelongitudinal rail (231) and at least two transverse rails (232) withassociated drives systems to impart controlled and precise relativemovement is well known in the art of CNC machining operations.

Next, the at least one work tool (200) will be described. As previouslymentioned, the at least one work tool (200) is movably mounted to thecarrier frame (230), as seen in FIG. 3, thus allowing the at least onework tool (200) to move precisely along the X-axis and Y-axis. The atleast one work tool (200) is utilized to remove mortar from at least aportion of one of the plurality of joints (J) between the plurality ofmasonry units (MU). Generally, the at least one work tool (200) is heldby a tool holder, such as a chuck, that is attached to a spindle with anassociated motor to drive the rotary motion of the at least one worktool (200). As one with skill in the art will recognize, the at leastone work tool (200) may be powered electrically, pneumatically, orhydraulically.

In one embodiment, the at least one work tool (200) may comprise a firstwork tool and a second work tool. The first work tool may be entirelyseparate from the second work tool, with each work tool separatelymovably mounted to the carrier frame (230). As will be discussed in moredetail below, the first work tool may be utilized to remove mortar fromat least a portion of one of the plurality of joints (J) extendingsubstantially along the X-axis, while the second work tool may beutilized to remove mortar from at least a portion of one of theplurality of joints (J) extending substantially along the Y-axis.

In one particular embodiment, the at least one work tool (200) comprisesa circular blade (211), as seen in FIGS. 7-9. Preferably, the circularblade (211) is a diamond tool, meaning that the circular blade (211) hasdiamond grains secured to its cutting edges. A diamond tool is preferredbecause they are well suited for cutting and grinding highly abrasivematerial, such as mortar. The circular blade (211) is especiallypreferred for removing mortar from the plurality of joints (J) thatextend substantially along the X-axis. A circular blade (211) that iseffective for removing mortar along the X-axis will generally not beeffective for removing mortar along the Y-axis. This is because thediameter of the circular blade (211) will likely be larger than thewidth and height of the joints (J) that extend substantially along theY-axis, and thus the circular blade (211) would damage the masonry units(MU) if used to remove mortar along the Y-axis. Of course, this dependson the size of the circular blade (211) being used to remove the mortar,and it is envisioned that a smaller diameter circular blade (211) may beutilized to remove mortar from joints (J) that extend substantiallyalong the X-axis or Y-axis.

In another embodiment, the at least one work tool (200) comprises arouter-type bit (212), as seen in FIG. 5, which may be circular ornon-circular. As with the circular blade (211), the router-type bit(212) is preferably a diamond tool. The router-type bit (212) isespecially preferred for removing mortar from the plurality of joints(J) that extend substantially along the Y-axis. However, the router-typebit (212) may be effectively utilized to remove mortar from theplurality of joints (J) that extend along the X-axis and Y-axis.

In addition to being movable along the X-axis and Y-axis, the at leastone work tool (200) is also configured to move along a Z-axis, whichextends toward and away from the masonry structure (MS), as illustratedin FIGS. 4 and 5. To provide for movement along the Z-axis, the at leastone work tool (200) may be mounted on a guide driven by means of a ballscrew drive, hydraulically, or by means of linear motors. As will bediscussed in more detail below, the ability of the at least one worktool (200) to move precisely along the Z-axis allows the depth at whichthe mortar is removed from the plurality of joints (J) to be controlled.

Although the disclosure discusses the at least one work tool (200) asbeing primarily a rotary type mechanical tool, other embodiments areenvisioned. For example, one with skill in the art would recognize thatthe at least one work tool (200) may employ traditional mechanicalmaterial removal technology, laser technology, water jet or knifetechnology, air jet or knife technology, or ultrasonic technologycapable of removing mortar may be utilized.

Referring now to FIGS. 4-8, the system (10) includes a containmentsystem (300) for collecting dust and debris generated as the at leastone work tool (200) removes mortar from at least a portion of one of theplurality of joints (J) between the plurality of masonry units (MU). Aspreviously mentioned, when mortar is removed from at least a portion ofone of the plurality of joints (J), the removal process generates silicadust that can be inhaled by workers, which can result in silicosis, adisabling and many times fatal disease that affects the lungs. Thus, theprovision of a containment system (300) improves worker safety byeffectively containing and removing the dust and debris that isgenerated when the at least one work tool (200) removes mortar from atleast a portion of one of the plurality of joints (J).

As seen in FIGS. 4-8, the containment system (300) includes a suctionhood (310) for enclosing the at least one work tool (200). The suctionhood (310) is in contact with the masonry structure (MS) around at leastfifty percent of the perimeter of the suction hood (310) so as tocontain dust and debris, and facilitate its removal. The suction hood(310) may be formed of various materials, including but not limited tolight weight metals, acrylics, polycarbonates, vinyl, and other plasticmaterials, just to name a few. The suction hood (310) may include aseries of bristles (311) that engage the masonry structure (MS), as seenin FIG. 7, to accommodate movement of the suction hood (310) while stillmaintaining an effective barrier. In another embodiment, the suctionhood (310) includes at least one biased deflector (312) that engages themasonry structure (MS) to create a barrier, as seen in FIG. 8. In oneembodiment the width of the biased deflector (312) is less than thespace between adjacent masonry units (MU). Such a biased deflector (312)is particularly beneficial when situated in-line with the at least onework tool (200) such that the biased deflector (312) extends into theregion behind the work tool (200) where mortar has already been removedand effectively blocks a majority of the debris flying off the work tool(200) from leaving through the newly created void in the mortar. Thebias force of the biased deflector (312) is such that pieces of mortarleaving the work tool (200) at high velocity do not cause the biaseddeflector (312) to rotate and allow passage of the debris, yet the biasforce is not so great as to create considerable resistance to themovement of the suction hood (310). In one particular embodiment, thebiased deflector (312) is configured to accommodate movement of thesection hood (310) in at least two directions, as seen in FIG. 8. In yeta further embodiment, the length of the biased deflector (312) is atleast ten percent of the diameter of the work tool (200) and less thanforty-five percent of the diameter of the work tool (200). While thebiased deflector (312) is generally constructed of a rigid material suchas metal or plastic, one particular embodiment incorporates a resilientmaterial for at least fifty percent of the length of the biaseddeflector (312). In this embodiment, the resilient portion facilitateschanges in travel direction without having to move the suction hood(310) away from the masonry structure (MS) during changes in direction.The resilient portion may include a plurality of metal bristles or arubber-like composition. It should be noted that while the term suctionhood (310) is used herein, this does not imply that the suction hood(310) creates a vacuum or other area of reduced pressure within thesuction hood (310); rather, merely that it is a hood connected to anexhaust system to contain and remove a significant amount of dust anddebris from the vicinity of the work tool (200).

Referring to FIGS. 4 and 5, the containment system (300) also includes avacuum system (320), which may broadly include any type of exhaustsystem. The vacuum system (320) may include a remote exhaust system thatis connected to the containment system (300) via conduits, or the vacuumsystem (320) may be a local unit that travels with the work tool (200)such as a portable centrifugal dust collection system that captures andcontains debris near the source. In the remote embodiment, the vacuumsystem (320) may be secured to the suction hood (310), such as byflexible hoses (315), as shown in FIG. 5. The vacuum system (320) may bea single-stage system or a two-stage system. The vacuum system (320)includes a vacuum source for creating a pressure differential to causeair to flow through the suction hood (310), which draws the dust anddebris out of the suction hood (310) for collection by the vacuum system(320). In a typical two-stage system, the larger debris is separatedfrom the dust and finer particles with a collection device, such as acyclone or a canister. From this point, the air containing the dust andfiner particles is typically filtered, such as by passing through a highefficiency filter, before being exhausted to the atmosphere. In oneembodiment the vacuum system (320) includes at least one HEPA filter.

The general operation of the system (10) for mortar removal isaccomplished in an automated manner through a computer control system(400). As seen schematically in FIGS. 4 and 5, the computer controlsystem (400) is in communication with the joint identification device(100) and the at least one work tool (200). The communication betweenthe computer control system (400) and the joint identification device(100) and the at least one work tool (200) may be achieved with USB,RS-422, RS-485, or wireless connections, just to name a few. As aresult, the computer control system (400) is capable of sending andreceiving electrical signals representative of commands and/or data toand from the joint identification device (100) and the at least one worktool (200). Generally, the computer control system (400) includes amemory for storing a system software element and a processing unit forinterpreting and executing instructions generated by the systemsoftware. This general embodiment of the computer control system (400)includes aspects that are similar to conventional CNC (computernumerical control) units, which are well known in the art. The computercontrol system (400) may be a personal computer system, traditionalcentral processing unit, or virtually any processor platform. Thecomputer control system (400) may also be in communication with adisplay (410) for graphically illustrating various data and theoperation of the system (10), as well as one or more input devices (420)such as a keyboard or mouse to allow an operator to input manualcommands and generally oversee the operation of the system (10). Oneparticular embodiment includes a manual data collection device that anoperator may use to physically trace complex joint (J) configurations,such as around arches, and transfer the data to the computer controlsystem (400) for additional control of the automated mortar removalprocess.

The computer control system (400) receives the joint location data fromthe joint identification device (100) and computes a work path (WP)based upon the joint location data. As previously mentioned, the jointlocation data may include the X, Y, and Z coordinates associated with atleast one of the plurality of joints (J). In addition, and as mentionedabove, joint dimension data, including the length, width, and depth ofat least one of the plurality of joints (J), may be transmitted to thecomputer control system (400). In essence, the computer control system(400) processes the joint location data to create a map, or work path(WP), of at least one of the plurality of joints (J) from which mortaris to be removed. After the work path (WP) has been computed, thecomputer control system (400) controls the position and operation of theat least one work tool (200) such that the at least one work tool (200)removes mortar from at least a portion of one of the plurality of joints(J) along the work path (WP). The positioning and movement of the atleast one work tool (200) is controlled by the computer control system(400) issuing commands to controllers associated with the X-axis,Y-axis, and Z-axis drive systems. The computer control system (400) mayalso be capable of controlling speed, change in direction, and moveenable/disable for each axis. Moreover, the computer control system(400) controls the operation of the at least one work tool (200) byissuing enable/disable commands to a controller associated with the worktool motor. Still further, the computer control system (400) may also becapable of controlling the speed of the work tool motor to increase ordecrease the rotary speed of the at least one work tool (200). In afurther embodiment, at least one temperature sensor monitors thetemperature of the work tool (200) to temporarily pause the materialremoval process, or slow down the process, if the temperature of thework tool (200) exceeds a predetermined level, thereby reducing toolwear and extending the life of the tool.

Controlling the position of the at least one work tool (200) along theZ-axis is important to the success of the system (10) for mortarremoval. As mentioned previously, the standard depth at which mortar istypically removed from the plurality of joints (J) is about 0.75 inchesto about 1.0 inch. In one embodiment, the method for removing mortarincludes the step of controlling the position of the at least one worktool (200) along a Z-axis such that mortar is removed from at least aportion of one of the plurality of joints (J) along the work path (WP)at a predetermined depth. The predetermined depth, typically about 0.75inches to about 1.0 inch, may be set and input into the computer controlsystem (400) by an operator. As noted above, the joint identificationdevice (100) may transmit the joint location data and/or the jointdimension data to the computer control system (400). Based upon thisdata, the computer control system (400) is capable of determining thedistance between the at least one work tool (200) and at least one ofthe plurality of joints (J) along the work path (WP) at any give pointon the work path (WP). Next, the computer control system (400) controlsthe position of the at least one work tool (200) along the Z-axis sothat the at least one work tool (200) moves to the predetermined depthwhen operating to remove the mortar. It should be noted that the depthof the plurality of joints (J) along the work path (WP) is likely to bevariable along the length of the work path (WP), and thus the distanceat which the at least one work tool (200) moves along the Z-axis may becontinuously variable as determined by the joint identification device(100) and the computer control system (400). This helps ensure that themortar being removed from at least a portion of one of the plurality ofjoints (J) along the work path (WP) is consistently removed at thepredetermined depth for all points along the work path (WP). In anotherembodiment, the computer control system (400) includes a constant depthremoval control system in which the system monitors variations in theface of the masonry and adjusts the position of the work tool (200) toensure that a constant depth of mortar removal is maintained. Buildingupon this embodiment, the computer control system (400) may activelymonitor the amount of mortar removed and adjust the position of the worktool (200) in the Z direction to account for tool wear. A still furtherembodiment of the computer control system (400) allows an operator tographically select regions for an alternate mortar removal depth. Forinstance, the operator may select discreet regions of the masonrystructure (MS) in which more, or less, mortar is to be removed toaccount for variations in the condition of the mortar or to account forstructural considerations.

In one particular embodiment, the method for removing mortar from theplurality of joints (J) between the plurality of masonry units (MU) mayfurther comprise the step of sensing the depth of at least a portion ofone of the plurality of joints (J) along the work path (WP) after mortarhas been removed and transmitting joint depth data to the computercontrol system (400). This step provides a method for verifying that theat least one work tool (200) removed mortar from at least a portion ofone of the plurality of joints (J) along the work path (WP) at thepredetermined depth. This may be accomplished by moving the jointidentification device (100) over the work path (WP) after mortar hasbeen removed and sensing the depth along the work path (WP) andtransmitting the joint depth data to the computer control system (400).Alternatively, the system (10) may include a second joint identificationdevice (100) that follows after the at least one work tool (200) alongthe work path (WP) when the at least one work tool (200) is operating toremove mortar.

Additionally, the method may include the steps of comparing the jointdepth data to the predetermined depth to generate a joint depthdifferential, and further removing mortar from at least a portion of oneof the plurality of joints (J) along the work path (WP) until the jointdepth differential is substantially zero, which for purposes of thisdisclosure is about 0.05 inches. In these steps, the computer controlsystem (400) will compare the joint depth data transmitted by the jointidentification device (100) with the predetermined depth input by theoperator. As a result, the computer control system (400) will generate ajoint depth differential, which is basically the difference between thejoint depth sensed by the joint identification device (100) after mortarhas been removed and the predetermined depth input by the operator.Next, the computer control system (400) will control the at least onework tool (200) to further remove mortar along points of the work path(WP) where a joint depth differential exists. The process may berepeated until the joint depth differential is substantially zero, thusassuring that the mortar is removed from at least a portion of one ofthe plurality of joints (J) along the work path (WP) at thepredetermined depth.

Referring now to the schematic of FIG. 5, the system (10) for mortarremoval may further include a color contrast sensor (120) incommunication with the computer control system (400). The color contrastsensor (120) is preferably movably mounted to the carrier frame (230) inthe same way the joint identification device (100) and the at least onework tool (200) are mounted. Further, the color contrast sensor (120)should be mounted such that it is fixed on the same horizontal axis(X-axis) as the joint identification device (100) and the at least onework tool (200). Specifically, the color contrast sensor (120) ismounted such that it is capable of moving along the work path (WP) inthe same way as the at least one work tool (200) moves along the workpath (WP). The color contrast sensor (120) is capable of sensing a colorcontrast along the work path (WP) and transmitting color contrast datato the computer control system (400). Examples of the color contrastsensor (120) include the CNTX advanced contrast sensor and the CMYXcolor sensor available from EMX Industries, Inc. of Cleveland, Ohio. Thecolor contrast sensor (120) may represent the color contrast data asintegers that correspond to varying levels of color and/or colorcontrast. In one embodiment, the color contrast sensor (120) mayincorporate infrared sensing technology. During mortar removal, the dustthat is generated in the containment system (300) will create low lightconditions that may interfere with the operation of the color contrastsensor (120). To allow the color contrast sensor (120) to operate insuch low light conditions, the color contrast sensor (120) may includean infrared emitter for emitting an infrared light source and aninfrared sensor for sensing the infrared light.

For the vast majority of masonry structures (MS), the mortar in theplurality of joints (J) will be a different color than the masonry units(MU). For example, the mortar may be a light gray color and the masonryunits (MU) may have a red color. Thus, in one embodiment, when the colorcontrast sensor (120) is positioned over the light gray colored mortaralong the work path (WP) it may represent the color contrast data as aninteger within a range of 1 to 5, for example, and when the colorcontrast sensor (120) is positioned over a red masonry unit (MU) it mayrepresent the color contrast data as an integer within a range of 10 to15, just as an example. As a result, an operator may input apredetermined color contrast into the computer control system (400) thatcorresponds to the color contrast data representative of the light graycolored mortar along the work path (WP), e.g., within the range of 1 to5. Moreover, the computer control system (400) may be programmed toalter the operation of the at least one work tool (200) when the colorcontrast data received by the computer control system (400) exceeds thepredetermined color contrast input by the operator. For example, thecomputer control system (400) may reposition the at least one work tool(200) to a point along the work path (WP) where the sensed colorcontrast is within the range of the predetermined color contrast. Suchan embodiment ensures that the material the at least one work tool (200)is about to remove is actually the mortar and not the masonry units(MU). In another embodiment, the computer control system (400) may beprogrammed to alter the operation of the at least one work tool (200)when the color contrast data received by the computer control system(400) differs from the predetermined color contrast input by theoperator by a predetermined amount. By stopping the operation of the atleast one work tool (200), the operator has an opportunity to verifythat only mortar is being removed and that the masonry units (MU) arenot being damaged, thus protecting the integrity of the masonrystructure (MS) and prolonging the working life of the at least one worktool (200).

In one embodiment, the vacuum system (320) includes a color sensor thatis in electrical communication with the computer control system (400).The color sensor is capable of monitoring the color of the dust anddebris that is collected during the mortar removal process. The colorsensor may incorporate the features listed above with respect to thecolor contrast sensor (120). For example, an operator may input apredetermined color value into the computer control system (400) thatcorresponds to the color value representative of the mortar along thework path (WP). The computer control system (400) may be programmed toalter the operation of the at least one work tool (200) when the colorvalue data transmitted by the color sensor and received by the computercontrol system (400) exceeds the predetermined color value input by theoperator. This particular embodiment adds an additional level of controlto ensure that only mortar is being removed and that the masonry units(MU) are not being damaged, thus protecting the integrity of the masonrystructure (MS) and prolonging the working life of the at least one worktool (200).

In another embodiment, the method for removing mortar may furthercomprise the step of sensing a work path load applied against the atleast one work tool (200) when removing mortar from at least a portionof one of the plurality of joints (J) along the work path (WP) andtransmitting work path load data to the computer control system (400).To accomplish this step, the at least one work tool (200) may include awork path load sensor (270) for sensing the resistive load on the atleast one work tool (200) as it traverses along the work path (WP)removing mortar, as seen in FIG. 5. For example, the work path loadsensor (270) may comprise load cells, a piezoelectric sensor, or anyother device that can accurately measure and transmit the travel axisload experienced by the work tool (200) as work path load data to thecomputer control system (400). The computer control system (400) maymonitor the work path load and adjust the speed that the work tool (200)is traversing the work path (WP) to increase productivity when the workpath load is below a threshold work path load value, or to decrease thetravel speed if the threshold work path load value is exceeded. Thisvariable travel speed control embodiment facilitates increasedproductivity while reducing the risk of premature tool breakage if aparticularly hard portion of mortar is experienced. Yet anotherembodiment incorporates this same strategy, but in a different manner byincorporating a torque sensor to measure and transmit the torqueexperienced by the at least one work tool (200) and adjusts the travelaxis speed accordingly. Yet even a further embodiment achieves thistravel speed control by monitoring the electrical current draw of thework tool (200) and adjusting the travel speed accordingly.

Each of these methods of controlling the travel speed may further beused as a safety to sense when the work tool (200) has cut intosomething other than mortar and prevent further movement of the worktool (200). For instance, monitoring the work path load experienced bythe at least one work tool (200) is another way in which the operationof the at least one work tool (200) may be verified to ensure that theat least one work tool (200) is removing mortar from at least a portionof one of the plurality of joints (J) along the work path (WP) and isnot damaging the masonry units (MU). In nearly all masonry structures(MS) the mortar will be relatively softer than the masonry units (MU).This is particularly true when the mortar has deteriorated over time andneeds to be removed. As purely an example, the at least one work tool(200) may experience a work path load within a range of about 5 lbf toabout 10 lbf when removing mortar, and may experience a work path loadwithin the range of about 20 lbf to about 50 lbf when coming intocontact with a masonry unit (MU). Thus, an operator may input apredetermined work path load into the computer control system (400) thatcorresponds to the work path load data representative of the resistivetravel axis load experienced by the at least one work tool (200) whenthe at least one work tool (200) removes mortar from at least a portionof one of the plurality of joints (J) along the work path (WP), e.g.,within the range of about 5 lbf to about 10 lbf. Moreover, the computercontrol system (400) may be programmed to alter the operation of the atleast one work tool (200) when the work path load data received by thecomputer control system (400) exceeds the predetermined work path loadinput by the operator. For example, the computer control system (400)may reposition the at least one work tool (200) to a point along thework path (WP) where the work path load is within the range of thepredetermined work path load. Such an embodiment ensures that thematerial that the at least one work tool (200) is removing is the mortarand not the masonry units (MU). In another embodiment, the computercontrol system (400) may be programmed to stop, or alter, the operationof the at least one work tool (200) when the work path load datareceived by the computer control system (400) exceeds the predeterminedwork path load input by the operator. By stopping, or altering, theoperation of the at least one work tool (200), the operator has anopportunity to verify that only mortar is being removed and that themasonry units (MU) are not being damaged, thus further protecting theintegrity of the masonry structure (MS) and prolonging the working lifeof the at least one work tool (200).

Even further in another embodiment, each of these methods of controllingthe travel speed may be used by the computer control system (400) todetermine when a multiple pass approach is required. For example, amultiple pass approach is one in which one single pass of a work tool(200) past a particular location along the joint (J) does not remove allof the desired mortar by design; such as a first pass that removes fiftypercent of the desired depth and a second pass that removes theremaining fifty percent of the desired depth. In various embodiments thecomputer control system (400) may utilize any one of the previouslydiscussed feedback inputs, including, but not limited to, the resistivetravel axis load experienced by the at least one work tool (200), thetorque, the current draw, or the work tool temperature to recommend amultiple pass approach to the operator, or automatically determine thata multiple pass approach is appropriate and switch to such an approach.In such an embodiment, once a predetermined maximum value is reached thecomputer control system (400) automatically reduces the removal depth byat least twenty five percent and then proceeds on the prescribed course,and then proceeds to make a second pass to remove the remaining mortarto achieve the desired removal depth. Then, if a predetermined maximumvalue is again reached the computer control system (400) automaticallyreduces the original removal depth by at least fifty percent and thenproceeds on the prescribed course, and then proceeds to make a secondpass to remove the remaining mortar to achieve the desired removaldepth. In such embodiments having reduced travel axis speed, or multiplepasses so that less mortar is removed per foot of travel, a furtherembodiment of the computer control system (400) recognizes this and maythrottle back the containment system (300) to conserve energy, and/orreduce the flow from the air nozzle (214) to conserve energy and reducethe likelihood of additional wear on the masonry units (MU).

With reference now to FIG. 9, a portion of a masonry structure (MS) isshown with a representation of a work path (WP) computed by the computercontrol system (400). As seen in FIG. 9, the work path (WP) comprises ahorizontal work path (HWP) that extends substantially in the X-axisdirection, and a plurality of vertical work paths (VWP) that branch offof the horizontal work path (HWP) and extend substantially in the Y-axisdirection. As previously mentioned, a first work tool may be utilized toremove mortar from at least a portion of one of the plurality of joints(J) extending substantially in the X-axis direction, i.e., along ahorizontal work path (HWP), while a second work tool may be utilized toremove mortar from at least a portion of one of the plurality of joints(J) extending substantially in the Y-axis direction, i.e., along avertical work path (VWP). Thus, in one embodiment, the method forremoving mortar may further comprise the steps of utilizing the firstwork tool to remove mortar from at least a portion of one of theplurality of joints (J) along the horizontal work path (HWP), andutilizing the second work tool to remove mortar from at least a portionof one of the plurality of joints (J) along the vertical work path(VWP). In still another embodiment, the first work tool utilized alongthe horizontal work path (HWP) comprises a circular blade (211) tool,and the second work tool utilized along the vertical work path (VWP)comprises a router-type bit (212) tool. As mentioned above, the firstwork tool and the second work tool may be separate work tools that areseparately movably mounted to the carrier frame (230), or they may bethe same tool configured in a different manner.

Alternatively, in another embodiment, the method for removing mortarincludes the step of changing the at least one work tool (200) when thework path (WP) transitions from a horizontal work path (HWP) to avertical work path (VWP). Still further, the at least one work tool(200) for use on the horizontal work path (HWP) comprises a circularblade (211), and the at least one work tool (200) is changed to arouter-type bit (212) for use on the vertical work path (VWP).

To accomplish the step of changing the at least one work tool (200), thesystem (10) for mortar removal further comprises a tool changing system(220) in communication with the computer control system (400), as seenin FIG. 5. The tool changing system (220) is capable of selectivelychanging out the at least one work tool (200) when the work path (WP)transitions from a horizontal work path (HWP) to a vertical work path(VWP) or vice versa, or based upon variances in the size of a joint (J)or due to work tool (200) wear conditions. The tool changing system(220) includes a tool magazine (221) for holding a plurality of worktools (200), such as the circular blade (211) and a wire rotary brush(213), as seen in FIG. 5. The tool changing system (220) may be movablymounted on the carrier frame (230) near the at least one work tool (200)in the same manner as the joint identification device (100) and the atleast one work tool (200) are mounted. Moreover, the tool changingsystem (220) may be directly coupled to the at least one work tool (200)such that the tool changing system (220) moves synchronously with the atleast one work tool (200). The tool changing system (220) may alsoinclude a swivel arm to move the tool magazine (221) into alignment withthe at least one work tool (200) to effect an automatic tool change.

In operation, the computer control system (400) may transmit commandsignals to the tool changing system (220) and the at least one work tool(200) when it is determined that the work path (WP) is transitioningfrom a horizontal work path (HWP) to a vertical work path (VWP) or viceversa. The command signal sent to the at least one work tool (200) maybe a disable command to stop the operation of the at least one work tool(200). The command signal sent to the tool changing system (220) maymove the tool magazine (221) into alignment with the at least one worktool (200) and effect a tool change. Moreover, the computer controlsystem (400) may be configured to allow an operator to manually inputcommands to change the at least one work tool (200) at any point in themortar removal process, not just when the work path (WP) transitionsfrom a horizontal work path (HWP) to a vertical work path (VWP). Stillfurther, the tool magazine (221) may hold similar work tools (200) ofdifferent sizes and the tool changing system (220) may be utilized tochange a larger work tool (200) to a smaller work tool (200) based uponthe joint location data or the joint dimension data stored in thecomputer control system (400). For example, if the size of a joint (J)at a point along the work path (WP) becomes too narrow for a ¾ inch, forexample, router-type bit tool (212) to remove mortar without damagingthe adjacent masonry units (MU), then the ¾ inch router-type bit tool(212) may be automatically changed to a smaller ½ inch, for example,router-type bit tool (212). Moreover, the at least one work tool (200)may be changed due to the wear condition of the tool (200).

In a further embodiment, the computer control system (400) may beprogrammed to operate the work tool (200) to remove mortar from theplurality of joints (J) utilizing a multiple pass approach. A multiplepass approach is one in which a single pass of a work tool (200) past aparticular location along the joint (J) does not remove all of thedesired mortar by design; such as a first pass that removes fiftypercent of the mortar in the joint (J) at a desired depth, and a secondpass that removes the remaining fifty percent of the mortar in the joint(J) at the desired depth. The number of passes the work tool (200) maybe determined real-time by the computer control system (400) dependingon the size of the work tool (200) being utilized, as well as thedimensions and location of the joint (J). Moreover, the multiple passapproach may be utilized to ensure a more precise removal process, whichcreates a cleaner joint (J) for receiving new mortar.

In yet another embodiment, the method for mortar removal may furtherinclude the step of brushing at least a portion of one of the pluralityof joints (J) along the work path (WP) after mortar has been removed, asillustrated in FIGS. 6-8. As noted above, one of the plurality of worktools (200) held in the tool magazine (221) may be a wire rotary brush(213), as seen in FIG. 5, or a follower rotary brush may be a separateindependent tool. Thus, in one embodiment, after the mortar has beenremoved from the work path (WP), the at least one work tool (200) may bechanged via the tool changing system (220) to the wire rotary brush(213), which may then be operated to brush at least a portion of one ofthe plurality of joints (J) along the work path (WP). In anotherembodiment, the wire rotary brush (213) may be a separate tool movablymounted to the carrier frame (230) that is controlled to follow afterthe at least one work tool (200) as it operates along the work path(WP), as shown in FIGS. 6-8. Still further, the wire rotary brush (213)may be directly coupled to the at least one work tool (200) such that itmoves synchronously with the at least one work tool (200) as it operatesalong the work path (WP). Brushing at least a portion of one of theplurality of joints (J) after mortar has been removed further cleans thejoint (J) by removing any loose debris that may remain, thus properlypreparing the joint (J) to be filled with new mortar.

In a further embodiment, the method for mortar removal may include thestep of blowing air into at least a portion of one of the plurality ofjoints along the work path (WP) after mortar has been removed.Preferably, this step is performed after brushing the joint (J) alongthe work path (WP). This step may be accomplished by guiding an airnozzle (214) supplied with compressed air along the work path (WP), asseen in FIGS. 6-8. The air nozzle (214) may be mounted on the carrierframe (230), or alternatively may be directly coupled to the wire rotarybrush (213) such that it follows the wire rotary brush (213)synchronously along the work path (WP). This step further ensures thatthe joint (J) is clean by blowing out any dust or loose debris that mayremain after mortar removal and brushing. Thus, the air blown joint (J)will be properly prepared to be filled with new mortar.

As previously mentioned, the system (10) for mortar removal may includean access system (50) to raise and lower the components of the system(10), i.e., the joint identification device (100), the at least one worktool (200), and the containment system (300), along an exterior of themasonry structure (MS), as seen in FIG. 3. Preferably, the access system(50) is initially used to raise the system (10) to the top of themasonry structure (MS). The system (10) is then operated to removemortar from at least a portion of one of the plurality of joints (J).For example, and with continued reference to FIG. 3, the system (10) maybe operated to remove mortar from at least a portion of one of theplurality of joints (J) that is within the bounds of the carrier frame(230). After the mortar has been removed from at least a portion of oneof the plurality of joints (J) within the bounds of the carrier frame(230), the access system (50) may be utilized to lower, or raise, thesystem (10) to an area of the masonry structure (MS) where mortar hasyet to be removed. Thus, in this embodiment the access system (50)performs the positioning of the carrier frame (230) and then the worktool (200) performs high level positioning on, or within, the carrierframe (230).

In another embodiment, the system (10) may include multiple work tools(200) that are capable of simultaneous operation by the computer controlsystem (400). In this embodiment, the system (10) having multiple worktools (200) may be connected to the carrier frame (230), which ismounted to the access system (50), or multiple carrier frames (230).Alternatively, multiple carrier frames (230) that each carry a system(10) featuring a work tool (200) and a tool changing system (220) may bemounted to the access system (50). These particular embodiments serve toincrease the amount of mortar removal and decrease processing times.

The access system (50) may be any system capable of raising and loweringthe system (10) along the exterior of the masonry structure (MS), suchas hoist driven suspended platform systems and scissor lifts, just toname a couple. A preferred access system (50) is the SKYMASTER brandaccess system available from Sky Climber, LLC of Delaware, Ohio. TheSKYMASTER brand access system is a mast anchor system that utilizesstandard platforms and hoists without having to use top side rigging,and is disclosed in U.S. Patent Publication Nos. 20100032237 and20070000724, which are expressly incorporated by reference as ifcompletely written herein. The system (10) may be secured, for examplevia the carrier frame (230), to the rails of the lift platform of theaccess system (50). However, one with skill in the art will appreciatethat other arrangements for mounting the system (10) to the accesssystem (50) are possible. The right and left mast sections of the accesssystem (50) seen in FIG. 3 may include a plurality of targets of a knownsize, location, and orientation, which are easily recognizable by thecomputer control system (400) and aid in the processing of a work path(WP).

In a further series of embodiments, seen well in FIGS. 11-22, and whichare shown by means of illustration only and not limitation, variousapparatus and methods for removing mortar from a plurality of joints (J)between a plurality of conjoined masonry units (MU) in a verticalstationary masonry structure (MS) are illustrated. These embodiments maybe thought of as manual, or semi-automated, mortar removal methods andbenefit from tool movement assistance systems, and vibration dampingsystems, thereby facilitating the use of high power work tools, as wellas any of the features disclosed in the prior automated embodiments.

In one possible method, the method may include reversibly positioning amodular mast (1100) adjacent to a work area including a plurality ofconjoined masonry units (MU) having a plurality of joints (J), as seenwell in FIGS. 18-20. Again with reference to FIGS. 18-20, one canmovably secure a suspension work platform (1300) at a first suspensionwork platform working height and a tool support structure (700) at afirst tool support structure working height of at least six feet, to theat least a first modular mast (1100). The tool support structure (700)may be placed within a working distance of at least a first group ofconjoined masonry units (MU) having at least one joint (J). The term“working distance” indicates that the tool support platform (700) ispositioned such that an apparatus as shown in FIGS. 18-20 is within asafe and convenient distance of the area to be worked, and is in partdetermined by the scale of the apparatus and the masonry structure (MS),as would be known by one skilled in the art. In one embodiment the toolsupport platform may be locked to the at least a first modular mast(1100) by a support structure transverse locking system (710) having atleast one mast lock (712), as seen well in FIG. 20.

One can articulatably support a work tool (200), having a work toolweight, from an articulating arm system (500) articulatably coupled to awork tool orientation system (600) articulatably coupled to the toolsupport structure (700), as seen well in FIG. 11. A work tool positionmay be secured (200) against unintended movement in longitudinal,elevation, and depth directions.

FIGS. 11-17 show possible adjustments in freedom of motion for the worktool (200). In one embodiment, a roll of the work tool (200) may beadjusted to a desired initial roll position, as seen well in FIGS.12-13, and the work tool (200) locked in the desired initial rollposition. In another embodiment a pitch of the work tool (200) may beadjusted to a desired initial pitch position, as seen well in FIGS.14-15, and the work tool (200) may be locked in the desired initialpitch position. Similarly, in an even further embodiment, the work tool(200) may be adjusted to a desired initial yaw position, as seen in FIG.17, and the work tool (200) may be locked in the desired initial yawposition. One skilled in the art would realize that adjustments andlocking in any of the roll-pitch-yaw directions of freedom of movementmay be made in any order, and that all freedoms of motion might not needto be adjusted, or locked, at any particular point in time. In fact inone embodiment each degree of freedom has its own locking system toprovide great user flexibility and the ability to make on the flychanges to the location and/or orientation of the work tool (200).

The work tool (200) position may be adjusted to a desired initial worktool elevation and the work tool (200) then locked in elevationposition, and the work tool (200) may be adjusted to a desired initialcutting depth in at least a portion of a joint (J) between the pluralityof conjoined masonry units (MU). The work tool (200) may then be lockedat the desired initial cutting depth.

A further step may include advancing the work tool (200) in alongitudinal direction in at least a portion of the joint (J), as seenin FIG. 6, and removing mortar. When a desired amount and/or length ormortar has been removed, the work tool (200) may be unlocked from thedesired initial cutting depth position and removed from the joint (J).The tool support structure (700) may then be unlocked to allow movement.If it is desired to move the apparatus to a further work area, or tomake it easier or safer to access any portion of the work area, thesuspension work platform (1300) may be moved as needed from the firstsuspension work platform working height to a second suspension workplatform working height, again as seen well in FIGS. 18-20.

Similarly, and with reference again to FIGS. 18-20, the tool supportstructure (700), after unlocking the support structure transverselocking system (710), may be moved as needed from the first tool supportstructure working height to a second tool support structure workingheight within working distance of at least a second group of conjoinedmasonry units having at least one joint (J). The apparatus may bere-locked to the modular mast (1100) by the support structure transverselocking system (710) having at least one mast lock (712). The work tool(200) may be secured against unintended movement in longitudinal,elevation and depth directions.

As before, and again as seen well in FIGS. 12-17, the roll of the worktool (200) may be adjusted as needed to a desired second roll positionand the work tool (200) locked in the desired second roll position; thepitch of the work tool (200) may be adjusted as needed to a desiredsecond pitch position and the work tool (200) locked in the desiredsecond pitch position; and the yaw of the work tool (200) may beadjusted as needed to a desired second yaw position and the work tool(200) locked in the desired second yaw position. The work tool (200) maybe adjusted to a desired second work tool elevation and locked in thedesired second work tool elevation; and work tool (200) position may beadjusted to a desired second cutting depth in at least a portion of thejoint (J). The work tool (200) may be locked at the desired secondcutting depth.

Again, and as seen well in FIG. 6, the work tool (200) may be advancedin a longitudinal direction along a portion of the joint (J) and mortarremoved. The work tool (200) may be unlocked from the second cuttingdepth position and removed from the joint (J).

As additional work areas may need to be worked, it is possible to repeatthe steps above as many times as are necessary for complete coverage ofthe desired work area. When work is completed, the method may concludewith unsecuring and removing the suspension work platform (1300) and thetool support structure (700) from the modular mast (1100); and removingthe modular mast (1100) from the work area.

In some embodiments, the step of adjusting the work tool (200) positionto the initial work tool elevation may require the application of anexternal elevation adjustment force that is less than twenty percent ofthe work tool weight. Functionally counterweighting the work tool (200)in this manner may make it both easier and safer to manipulate the worktool (200). In other embodiments, the method may include the step ofengaging a multiple joint activation switch with a single touch to atleast lock the work tool (200) in the desired initial work toolelevation and lock the work tool (200) in the desired cutting depth.Similarly, the method may include the step of engaging a joint releaseswitch to individually unlock a single degree of freedom of motionselected from the group of motions consisting of the initial work toolelevation and the cutting depth. Additionally, the step of engaging amultiple joint activation switch with a single touch may further lockthe initial roll position. Such “one-touch” switching and releasemechanisms, as well as others that would be apparent to one skilled inthe art, may speed and simplify the operation of the method.

In another set of embodiments, as seen well in FIGS. 11 and 16-17, thearticulating arm system (500) may include a radial arm (510) having aradial arm height adjustment system (512) and a tilting arm (520) havinga tilting arm radial position joint (522). The step of adjusting thework tool (200) position to the desired initial work tool elevation mayinclude adjusting the height of the radial arm (510) and locking aradial arm height adjustment system joint (514). Similarly, the step ofadjusting the work tool (200) position to the desired cutting depthbetween the plurality of conjoined masonry units (MU) to in the desiredcutting depth may include adjusting the tilting arm (520) relative tothe radial arm (510) and locking a tilting arm radial position joint(522).

As stated above, various embodiments of the method may include, as wouldbe well-known to those skilled in the art, various “one-touch” lockingand release mechanisms so that multiple functions might be accomplishedwith a single adjustment or touch. These can also include the step ofengaging a multiple joint activation switch with a single touch to atleast lock the tilting arm vertical position joint (524) and the radialarm radial adjustment system joint (516). This may also include having astep of engaging a joint release switch to individually unlock a singlejoint selected from the group of joints consisting of the tilting armvertical position joint (524) and the radial arm radial adjustmentsystem joint (516). One skilled in the art will be able to envision manyother “one-touch” adjustments, and they are all intended to beencompassed by this specification.

In a certain set of other embodiments, seen well in FIGS. 11 and 16, thearticulating arm system (500) may include a radial arm (510) and atilting arm (520), and the step of adjusting the work tool (200)position to the desired initial work tool elevation may includeadjusting the elevation of the radial arm (510) with respect to toolsupport structure (700). A radial arm height adjustment system joint(514) may also be locked. Similarly, the step of adjusting the work tool(200) position to the desired cutting depth between the plurality ofconjoined masonry units (MU) to the desired cutting depth may includeadjusting the radial arm (510) with respect to the tool supportstructure (700) and locking a radial arm radial adjustment system joint(516).

Just as with the other “one-touch” adjustments noted above, the methodmay further include the step of engaging a multiple joint activationswitch with a single touch to at least lock the radial arm heightadjustment system joint (514) and the radial arm radial adjustmentsystem joint (516). And similarly again, a step of engaging a jointrelease switch may be employed to individually unlock a single jointsuch as the radial arm height adjustment system joint (514) and theradial arm radial adjustment system joint (516).

The method may, in yet other embodiments, seen well in FIGS. 18-20,involve activating a directional drive system (800) with a drive systemcontrol to move the articulating arm system (500), the work toolorientation system (600), and the work tool (200) along the longitudinaldirection. In one embodiment the directional drive system (800) is alinear actuator; and in a further embodiment the drive system (800)includes force feedback to adjust the travel speed. As seen well inFIGS. 11-17, the work tool orientation system (600) may be athree-gimbal work tool orientation system (600) mounting allowingsimultaneous adjustment of the roll, pitch, and yaw of the work tool(200).

Various methods may be used to position the apparatus. The suspensionwork platform (1300) may be independently height-adjustable from thetool support structure (700), as seen well in FIGS. 18-19, or thesuspension work platform (1300) may be coupled to the tool supportstructure (700) as seen in FIGS. 20-22. As one skilled in the art wouldrealize, the steps of height adjustment of the work suspension platform(1300) and the tool support structure (700) are combined in thoseembodiments in which those structures are joined. While in someembodiments the suspension work platform (1300) and the tool supportstructure (700) are seen as independent structures in a verticalarrangement, they may also be visualized as independent, or joinedstructures in a parallel arrangement, as seen well in FIGS. 21-22.

In one series of embodiments, seen well in FIGS. 18-20, the step ofmoving the tool support structure (700) may be carried out by at leastone support structure hoist system cable (910) powered by at least onesupport structure hoist system lift (900). Similarly, and also withreference to FIGS. 18-20, the step of moving the suspension workplatform (1300) may be carried out by a suspension work platform hoistsystem lift (1430).

Similarly, more than one modular mast (1100) may be employed, andtherefore the step of securing a suspension work platform (1300) and atool support structure (700) to a modular mast (1100), would include thestep of securing the suspension work platform and the tool supportstructure (700) to a second mast (1200), or further masts (1100, 1200),as required. As would easily be seen by one skilled in the art, a secondsuspension work platform cable (1420) and a second suspension workplatform hoist system lift (1440) may be employed for greater stability.

In embodiments of the method employing multiple masts (1100, 1200), thestep of unsecuring and removing the suspension work platform (1300) andthe tool support structure (700) from the modular mast (1100) wouldfurther include the step of unsecuring and removing the suspension workplatform (1300) and the tool support structure (700) from any othermodular masts (1200). Similarly, with multiple masts (1100, 1200)employed, the step of removing the modular mast (1100) from the workarea would further include the step of removing any other modular masts(1200) from the work area.

In another embodiment the method includes the steps of: a) elevating asuspension work platform (1300) and a tool support structure (700) to aworking height of at least six feet and securing the tool supportstructure (700) to prevent movement in a transverse Z-direction; b)supporting a work tool (200), having a work tool weight, from the toolsupport structure (700) with a work tool orientation system (600)secured to the work tool (200), and an articulating arm system (500)secured to the work tool orientation system (600) and the tool supportstructure (700); c) adjusting the work tool (200) position to a desiredinitial work tool elevation and locking the work tool (200) in thedesired initial work tool elevation; d) adjusting a roll of the worktool (200) to a desired initial roll position and locking the work tool(200) in the desired initial roll position; e) adjusting the work tool(200) position to a desired cutting depth between the plurality ofconjoined masonry units (MU) and locking the work tool (200) in thedesired cutting depth; f) advancing the work tool (200) in alongitudinal X-direction along a portion of at least one of theplurality of joints (J) and removing mortar; g) unlocking the desiredcutting depth position and removing the work tool (200) from between theconjoined masonry units (MU), and releasing the tool support structure(700) to allow movement; h) elevating the tool support structure (700)to a second working height and securing the tool support structure (700)to prevent movement in a transverse Z-direction; i) adjusting the worktool (200) position to a second cutting depth between the plurality ofconjoined masonry units (MU) and locking the work tool (200) in thesecond desired cutting depth; j) advancing the work tool (200)longitudinally along a portion of at least one of the plurality ofjoints (J) and removing mortar; and k) unlocking the second cuttingdepth position and removing the work tool (200) from between theconjoined masonry units (MU).

In one particular embodiment the step of elevating the tool supportstructure (700) is independent of the step of elevating the suspensionwork platform (1300), such as that seen in FIG. 19. In one embodimentthe tool support structure (700) is totally separate from the suspensionwork platform (1300), and the elevation of the tool support structure(700) is controlled by at least one support structure hoist system lift(900), however in an alternative embodiment the tool support structure(700) may be attached to a boom-type lift mechanism. Similarly, and alsowith reference to FIGS. 18-20, the step of moving the suspension workplatform (1300) may be carried out by a suspension work platform hoistsystem lift (1430), or in an alternative embodiment via a boom-type liftmechanism. Further, as seen in FIG. 18, the tool support structure (700)may be totally separate from the suspension work platform (1300), yetstill have its elevation adjusted via the movement of the suspensionwork platform (1300). In yet another embodiment, seen in FIG. 20, thetool support structure (700) is attached to the suspension work platform(1300), and at least one suspension work platform hoist system lift(1430) adjusts the elevation of the suspension work platform (1300).

Just as the tool support structure (700) may be independent or attachedto the suspension work platform (1300), the step of securing the toolsupport structure (700) to prevent movement in a transverse Z-directionmay be independent or attached to the suspension work platform (1300).In one embodiment the at least one support structure transverse lockingsystem (710) releasably attaches directly to the vertical stationarymasonry structure (MS), and may secure directly to the tool supportstructure (700) or via the suspension work platform (1300). This may beaccomplished by vacuum pads, anchors, or any other mechanism known inthe field of suspension work platforms. Other embodiments incorporatemodular masts whereby the suspension work platform (1300) is suspendedfrom at least a first modular mast (1100) and the step of securing thetool support structure (700) to prevent movement in a transverseZ-direction includes securing at least one support structure transverselocking system (710) to the first modular mast (1100), such as a mastlocking device (712) as seen in FIG. 18, which may be as simple as aguided roller system.

In a further embodiment the work tool orientation system (600) includesa containment system (300), such as those previously described. Oneembodiment includes a suction hood (310) for enclosing the at least onework tool (200), and may incorporate a blade viewing window so that theoperator may visually examine the progress of the removal process andmake adjustments on the fly.

Numerous alterations, modifications, and variations of the preferredembodiments disclosed herein will be apparent to those skilled in theart and they are all anticipated and contemplated to be within thespirit and scope of the method and system (10) for mortar removal, asclaimed below. For example, although specific embodiments have beendescribed in detail, those with skill in the art will understand thatthe preceding embodiments and variations can be modified to incorporatevarious types of substitute and or additional or alternativemanufacturing processes and materials, relative arrangement of elements,and dimensional configurations. Accordingly, even though only fewvariations of the method and system (10) are described herein, it is tobe understood that the practice of such additional modifications andvariations and the equivalents thereof, are within the spirit and scopeof the method and system (10) as defined in the following claims. Thecorresponding structures, materials, acts, and equivalents of all meansor step plus function elements in the claims below are intended toinclude any structure, material, or acts for performing the functions incombination with other claimed elements as specifically claimed.

We claim:
 1. A method for removing mortar from a plurality of joints (J) between a plurality of conjoined masonry units (MU) in a vertical stationary masonry structure (MS), comprising: a) elevating a suspension work platform (1300) to a working height of at least six feet; b) supporting a work tool (200), having a work tool weight, from an articulating arm system (500) attached to the work tool (200) and the suspension work platform (1300); c) adjusting the work tool (200) position to a desired initial work tool elevation; d) adjusting the work tool (200) position to a desired cutting depth between the plurality of conjoined masonry units (MU); e) advancing the work tool (200) in a longitudinal X-direction along a portion of at least one of the plurality of joints (J) and removing mortar; f) removing the work tool (200) from between the conjoined masonry units (MU); g) elevating the work tool (200) to a second working height; h) adjusting the work tool (200) position to a second cutting depth between the plurality of conjoined masonry units (MU); i) advancing the work tool (200) longitudinally along a portion of at least one of the plurality of joints (J) and removing mortar; and j) removing the work tool (200) from between the conjoined masonry units (MU).
 2. The method of claim 1, wherein at least one suspension work platform hoist system lift (1430) adjusts the elevation of the suspension work platform (1300).
 3. The method of claim 2, wherein the step of adjusting the work tool (200) position to the initial work tool elevation requires the application of an external elevation adjustment force that is less than twenty percent of the work tool weight.
 4. The method of claim 3, wherein the articulating arm system (500) includes a radial arm (510) and a tilting arm (520), wherein the step of adjusting the work tool (200) position to the desired initial work tool elevation includes adjusting the tilting arm (520) with respect to the radial arm (510).
 5. The method of claim 4, wherein the step of adjusting the tilting arm (520) with respect to the radial arm (510) further includes locking a tilting arm vertical position joint (524) that joins the radial arm (510) and the tilting arm (520).
 6. The method of claim 4, wherein the step of adjusting the work tool (200) position to the desired cutting depth between the plurality of conjoined masonry units (MU) in the desired cutting depth includes adjusting the radial arm (510) with respect to the suspension work platform (1300).
 7. The method of claim 6, wherein the step of adjusting the radial arm (510) with respect to the suspension work platform (1300) further includes and locking a radial arm radial adjustment system joint (516).
 8. The method of claim 3, wherein the articulating arm system (500) includes a radial arm (510) and a tilting arm (520), wherein the step of adjusting the work tool (200) position to the desired initial work tool elevation includes adjusting the elevation of the radial arm (510) with respect to the suspension work platform (1300).
 9. The method of claim 8, wherein the step of adjusting the elevation of the radial arm (510) with respect to the suspension work platform (1300) further includes locking a radial arm height adjustment system joint (514).
 10. The method of claim 8, wherein the step of adjusting the work tool (200) position to the desired cutting depth between the plurality of conjoined masonry units (MU) in the desired cutting depth includes adjusting the radial arm (510) with respect to the suspension work platform (1300).
 11. The method of claim 10, wherein the step adjusting the radial arm (510) with respect to the suspension work platform (1300) further includes locking a radial arm radial adjustment system joint (516).
 12. The method of claim 1, further including the step of activating a unidirectional drive system (800), attaching the articulating arm system (500) to the suspension work platform (1300), with a drive system control to move the articulating arm system (500) and the work tool (200) along the longitudinal X-direction.
 13. The method of claim 1, further including a dust collection enclosure adjacent at least a portion of the work tool (200).
 14. The method of claim 13, wherein the dust collection enclosure includes a viewing window.
 15. A method for removing mortar from a plurality of joints (J) between a plurality of conjoined masonry units (MU) in a vertical stationary masonry structure (MS), comprising: a) elevating a suspension work platform (1300) to a working height of at least six feet using at least one suspension work platform hoist system lift (1430); b) supporting a work tool (200), having a work tool weight, from an articulating arm system (500) attached to the work tool (200) and the suspension work platform (1300); c) adjusting the work tool (200) position to a desired initial work tool elevation by the application of an external elevation adjustment force that is less than twenty percent of the work tool weight; d) adjusting the work tool (200) position to a desired cutting depth between the plurality of conjoined masonry units (MU); e) advancing the work tool (200) in a longitudinal X-direction along a portion of at least one of the plurality of joints (J) and removing mortar; f) removing the work tool (200) from between the conjoined masonry units (MU); g) elevating the work tool (200) to a second working height by the application of an external elevation adjustment force that is less than twenty percent of the work tool weight; h) adjusting the work tool (200) position to a second cutting depth between the plurality of conjoined masonry units (MU); i) advancing the work tool (200) longitudinally along a portion of at least one of the plurality of joints (J) and removing mortar; and j) removing the work tool (200) from between the conjoined masonry units (MU).
 16. The method of claim 15, wherein the articulating arm system (500) includes a radial arm (510) and a tilting arm (520), wherein the step of adjusting the work tool (200) position to the desired initial work tool elevation includes adjusting the tilting arm (520) with respect to the radial arm (510).
 17. The method of claim 16, wherein the step of adjusting the work tool (200) position to the desired cutting depth between the plurality of conjoined masonry units (MU) in the desired cutting depth includes adjusting the radial arm (510) with respect to the suspension work platform (1300).
 18. The method of claim 17, wherein the step of adjusting the work tool (200) position to the desired initial work tool elevation includes adjusting the elevation of the radial arm (510) with respect to the suspension work platform (1300).
 19. The method of claim 15, further including a dust collection enclosure adjacent at least a portion of the work tool (200).
 20. The method of claim 19, wherein the dust collection enclosure includes a viewing window. 